Artificial fiber log process

Abstract

A process for making an artificial mineral or ceramic fiber log representation having areas of enhanced thermal texturing that can be used in gas fireplaces to simulate the burning of real wood logs. The process uses a screen mold having simulated wood pattern elements to impart a realistic exterior surface to the artificial log and thermal reactive textured surface areas applied to said screen mold. A slurry of mineral fibers is injected under pressure into the mold forcing excess water therethrough leaving the fibers impinged within the mold. The log thus formed is dried in an oven and processed for additional decorative coatings.

Therefore I claim: 
     
       1. The method of molding a three-dimensional synthetic ceramic fiber log having areas of enhanced thermal surface treatment that can be used in gas fired fireplaces, the process comprises the steps of a. fitting a mold screen within a support mold, said support mold having a base portion and a top portion with a mold cavity therebetween,   b. depositing a thermal texturing paste over portions of said mold screen,   c. closing said support mold and introducing a ceramic fiber slurry under pressure within said mold cavity,   d. coalescing said ceramic fibers on the mold screen and thermal texturing paste portions within said support mold by injection of air pressure,   e. express drying said coalesced fibers by forcing excess liquid out of the mold cavity by air pressure,   f. capturing and recovering said excess liquid from said mold within a retainment enclosure,   g. removing said coalesce fibers in the form of an artificial fireplace log from said mold and drying said ceramic log at an elevated temperature during a second drying step.   
     
     
       2. The method set forth in claim 1 wherein said mold screen has a textured surface therein. 
     
     
       3. The method set forth in claim 1 wherein said support mold base and top have a plurality of elongated aligned grooves within. 
     
     
       4. The method set forth in claim 1 wherein said support mold base further has a first diversion screen conformed within. 
     
     
       5. The method set forth in claim 1 wherein said steps of depositing the thermal texturing paste on the mold screen employs, a nozzle and hose assembly connected to a source of thermal texturing material under pressure. 
     
     
       6. The method set forth in claim 1 wherein said step of introducing the ceramic fiber slurry under pressure employs a batch injection tank, a source of air pressure communication with said tank and valving means interconnecting same. 
     
     
       7. The method set forth in claim 1 wherein said step of coalescing said ceramic fibers into a log employs air pressure in the range of between 10 and 15 psi. 
     
     
       8. The method set forth in claim 1 wherein said step of excess express drying said coalesced fiber within said mold employs air pressure in the range of 35-40 psi. 
     
     
       9. The method set forth in claim 1 wherein the step of capturing and recovering said excess liquid from said mold within the retainment enclosure further employs a plurality of drain openings in said retainment enclosure interconnected with a recovery tank. 
     
     
       10. The method set forth in claim 3 wherein said elongated aligned grooves are in communication with the exterior of said mold base and top. 
     
     
       11. The method set forth in claim 1 wherein said support mold base and top further have a plurality of apertures within extending through apertures in said base and top. 
     
     
       12. The method of molding a three-dimensional synthetic ceramic fiber log having areas of increased thermal surface treatments that can be used in gas fired fireplaces, the process comprises the steps of a. fitting a mold screen within a support mold, said support mold having a base portion and a top portion with a mold cavity therebetween,   b. depositing vermiculite, a binder and a ceramic wool sheet on portions of said screen,   c. closing said support mold and introducing a ceramic fiber slurry under pressure within said mold cavity,   d. coalescing said ceramic fibers on the mold screen and the ceramic wool sheets and thermal texturing paste portions within said support mold by injection of air pressure,   e. express drying said coalesced fibers by forcing excess liquid out of the mold cavity by air pressure,   f. capturing and recovering said excess liquid from said mold within a retainment enclosure,   g. removing said coalesced fibers in the form of an artificial fireplace log from said mold and drying said ceramic log at an elevated temperature during a second drying step.   
     
     
       13. The method set forth in claim 12 wherein said mold screen has a textured surface therein. 
     
     
       14. The method set forth in claim 12 wherein said artificial fireplace log has area of enhanced thermal texturing within that reacts to heat input at a rate greater than that of the surrounding surfaces. 
     
     
       15. The method set forth in claim 12 wherein said support mold base and top have a plurality of elongated aligned grooves within. 
     
     
       16. The method set forth in claim 12 wherein said step of introducing the ceramic fiber slurry under pressure a batch injection tank, a source of air pressure communication with said tank and valving interconnecting means. 
     
     
       17. The method set forth in claim 12 wherein said step of coalescing said ceramic fibers into a log employs air pressure in the range of between 10 and 15 psi. 
     
     
       18. The method set forth in claim 12 wherein said step of excess express drying said coalesced fiber within said mold employs air pressure in the range of 35-40 psi. 
     
     
       19. The method set forth in claim 12 wherein the step of capturing and recovering said excess liquid from said mold within the retainment enclosure further employs a plurality of drain openings in said retainment enclosure interconnected with a recovery tank.